METHOD OF MANUFACTURING VEHICLE-MOUNTED CAMERA HOUSING, VEHICLE-MOUNTED CAMERA HOUSING, AND VEHICLE-MOUNTED CAMERA

• US 20160286101A1
• Filed: 06/14/2016
• Published: 09/29/2016
• Est. Priority Date: 03/17/2014
• Status: Abandoned Application

• Current Assignee: Nidec Elesys Corporation (Nidec Corporation)
• Original Assignee: Nidec Elesys Corporation (Nidec Corporation)
• Inventors: TAKEDA, Naoya
• Application Number:
  US15/181,626
• Publication Number:
  US 20160286101A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B22D 17/06 Air injection machines
• CPC Class Codes: B60R 11/04 Mounting of cameras operative during drive; Arrangement of controls thereof relative to the vehicle
• CPC Class Codes: B60R 2011/0026 Windows, e.g. windscreen
• CPC Class Codes: G01B 11/26 for measuring angles or tapers; for testing the alignment of axes
• CPC Class Codes: G03B 17/02 Bodies
• CPC Class Codes: G03B 17/12 with means for supporting objectives, supplementary lenses, filters, masks, or turrets
• CPC Class Codes: G06T 7/001 using an image reference approach
• CPC Class Codes: H04N 23/51 Housings
• CPC Class Codes: H04N 7/183 for receiving images from a single remote source
• CPC Class Codes: Y10T 29/49002 Electrical device making

Abstract

A method of manufacturing a vehicle-mounted camera housing including a cover housing, a camera main body and a circuit board includes providing a set of partial molds which are combined to form an internal cavity. When the combined partial molds are separated, an intermediate member is taken out and machined to obtain the cover housing. A top plate portion of the cover housing includes a pedestal extending downward. The machining includes cutting a distal end of the pedestal such that a flat face of the pedestal faces a predetermined direction with reference to an inclination angle of a windshield of a target vehicle, a relative direction of an optical axis of the camera, relative directions of the pedestal flat face and an upper surface of the top plate portion, and relative directions of the top plate and the windshield surface.

Claims

1. A method of manufacturing a vehicle-mounted camera including a cover housing including a tabular top plate section, a camera main body section fixed to the cover housing, and a circuit board connected to the camera main body section, the vehicle-mounted camera being attached to a windshield and used in a posture in which the top plate section extends along the windshield, the method comprising:

preparing a set of molds including a pair or three or more partial molds in which, when the partial molds are combined, an internal cavity including a tabular part sandwiched by a pair of inner surfaces is obtained;

combining the partial molds to form the internal cavity;

injecting a material in a fluidized state into the cavity;

solidifying the material;

separating the combined partial molds and taking out an intermediate member;

applying machine work to the intermediate member to obtain the cover housing;

fixing the camera main body section to the cover housing with a fixing member; and

connecting the circuit board and the camera main body, wherein

the camera main body section includes a lens unit,

the top plate section of the cover housing includes a pedestal extending downward,

the camera main body section includes, on a surface thereof, a camera flat face, which is a flat face,

a pair of inner surfaces of the molds that sandwich the tabular part in the internal cavity are surfaces of the partial molds different from each other,

one of the pair of inner surfaces includes a recessed section,

depth of the recessed section measured with reference to a flat part of the one inner surface is larger than height of the pedestal,

the machine work includes machining for cutting a distal end of the pedestal and forming a pedestal flat face, which is a flat face facing a predetermined direction,

in a state in which the camera main body section is fixed to the cover housing, the pedestal flat face and the camera flat face are in contact with each other, and

the predetermined direction is determined with reference to an inclination angle of the windshield of a target vehicle body, a relative direction of an optical axis of the lens unit with respect to the camera flat face, relative directions of the pedestal flat face and an upper face of the top plate section, and relative directions of the top plate and the windshield surface in a state in which the vehicle-mounted camera is attached to the windshield, wherein

the predetermined direction is determined with reference to a photographing direction in which the camera main body section photographs a scene and a tolerance allowed for the photographing direction,

the camera main body section includes a protrusion section for fixing that is a part extending in a direction away from the optical axis,

both of the material and the protrusion section for fixing are aluminum or an aluminum alloy,

the camera flat face is located on a surface of the protrusion section for fixing,

metal surfaces of both of the pedestal flat face and the camera flat face are exposed,

painting at least the upper face of the top plate section on a surface of the intermediate member, wherein

the machine work cuts at least a part of a painted surface of the intermediate member, and

the painting is executed before the camera main body section is fixed to the cover housing by the fixing member.

8. The method of manufacturing the vehicle-mounted camera according to claim 1, wherein

the circuit board includes a processing circuit element that electronically processes an image photographed by the camera main body section,

the processing circuit element includes an image processing program for using a direction error in processing the image photographed by the camera main body section,

the camera main body section after being attached to the windshield of the target vehicle body photographs a target object present in a known direction, which is a direction known with respect to the vehicle body, and causes the processing circuit element to acquire an image,

the processing circuit element recognizes an on-image position, which is a position of the target object on the image, the processing circuit element recognizes an original position, which is a position where the target object should originally be present on the image, on the basis of the known direction, and

the processing circuit element calculates the direction error using the original position and the on-image position.

12. The method of manufacturing the vehicle-mounted camera according to claim 1, wherein more than half of a lower face of the top plate section is a painted surface.

18. The method of manufacturing the vehicle-mounted camera according to claim 8, wherein more than half of a lower face of the top plate section is a painted surface.

2. A method of manufacturing a vehicle-mounted camera including a cover housing including a tabular top plate section, a camera main body section fixed to the cover housing, and a circuit board connected to the camera main body section, the vehicle-mounted camera being attached to a windshield and used in a posture in which the top plate section extends along the windshield, the method comprising:

preparing a set of molds including a pair or three or more partial molds in which, when the partial molds are combined, an internal cavity including a tabular part sandwiched by a pair of inner surfaces is obtained;

combining the partial molds to form the internal cavity;

injecting a material in a fluidized state into the cavity;

solidifying the material;

separating the combined partial molds and taking out an intermediate member;

applying machine work to the intermediate member to obtain the cover housing;

fixing the camera main body section to the cover housing with a fixing member; and

connecting the circuit board and the camera main body, wherein

the camera main body section includes a lens unit,

the top plate section of the cover housing includes a pedestal extending downward,

the camera main body section includes, on a surface thereof, a camera flat face, which is a flat face,

a pair of inner surfaces of the molds that sandwich the tabular part in the internal cavity are surfaces of the partial molds different from each other,

one of the pair of inner surfaces includes a recessed section,

depth of the recessed section measured with reference to a flat part of the one inner surface is larger than height of the pedestal,

the machine work includes machining for cutting a distal end of the pedestal and forming a pedestal flat face, which is a flat face facing a predetermined direction,

in a state in which the camera main body section is fixed to the cover housing, the pedestal flat face and the camera flat face are in contact with each other, and

the predetermined direction is determined with reference to an inclination angle of the windshield of a target vehicle body, a relative direction of an optical axis of the lens unit with respect to the camera flat face, relative directions of the pedestal flat face and an upper face of the top plate section, and relative directions of the top plate and the windshield surface in a state in which the vehicle-mounted camera is attached to the windshield,

assuming a plurality of inclination angles as the inclination angle of the windshield,

determining a plurality of the predetermined directions different from one another respectively in association with the assumed plurality of inclination angles,

preparing in advance a plurality the vehicle-mounted cameras respectively having any ones of the plurality of predetermined directions,

learning an attachment target inclination angle, which is an inclination angle of the windshield of the target vehicle body to which the vehicle-mounted camera is attached,

selecting an attachment target direction out of the plurality of predetermined directions with reference to the attachment target inclination angle,

selecting an attachment target vehicle-mounted camera, which is any one of the vehicle-mounted cameras having the attachment target direction as the predetermined direction,

attaching the attachment target vehicle-mounted camera to the windshield of the target vehicle body, and

painting at least the upper face of the top plate section on a surface of the intermediate member, wherein

the machine work cuts at least a part of a painted surface of the intermediate member,

the painting is executed before the camera main body section is fixed to the cover housing by the fixing member.

4. The method of manufacturing the vehicle-mounted camera according to claim 2, wherein the predetermined direction is determined further with reference to a photographing direction in which the camera main body section photographs a scene and a tolerance allowed for the photographing direction.

5. The method of manufacturing the vehicle-mounted camera according to claim 4, wherein

the camera main body section further includes a protrusion section for fixing that is a part extending in a direction away from the optical axis,

both of the material and the protrusion section for fixing are aluminum or an aluminum alloy,

the camera flat face is located on a surface of the protrusion section for fixing, and

metal surfaces of both of the pedestal flat face and the camera flat face are exposed.

9. The method of manufacturing the vehicle-mounted camera according to claim 2, wherein

the circuit board includes a processing circuit element that electronically processes an image photographed by the camera main body section,

the processing circuit element includes an image processing program for using a direction error in processing the image photographed by the camera main body section,

the camera main body section after being attached to the windshield of the target vehicle body photographs a target object present in a known direction, which is a direction known with respect to the vehicle body, and causes the processing circuit element to acquire an image,

the processing circuit element recognizes an on-image position, which is a position of the target object on the image,

the processing circuit element recognizes an original position, which is a position where the target object should originally be present on the image, on the basis of the known direction, and

the processing circuit element calculates the direction error using the original position and the on-image position.

10. The method of manufacturing the vehicle-mounted camera according to claim 2, wherein the predetermined direction is determined further with reference to a photographing direction in which the camera main body section photographs a scene and a tolerance allowed for the photographing direction.

13. The method of manufacturing the vehicle-mounted camera according to claim 2, wherein more than half of a lower face of the top plate section is a painted surface.

15. The method of manufacturing the vehicle-mounted camera according to claim 4, wherein more than half of a lower face of the top plate section is a painted surface.

19. The method of manufacturing the vehicle-mounted camera according to claim 9, wherein more than half of a lower face of the top plate section is a painted surface.

20. The method of manufacturing the vehicle-mounted camera according to claim 10, wherein more than half of a lower face of the top plate section is a painted surface.

3. A method of manufacturing a vehicle-mounted camera including a cover housing including a tabular top plate section, a camera main body section fixed to the cover housing, and a circuit board connected to the camera main body section, the vehicle-mounted camera being attached to a windshield and used in a posture in which the top plate section extends along the windshield, the method comprising:

preparing a set of molds including a pair or three or more partial molds in which, when the partial molds are combined, an internal cavity including a tabular part sandwiched by a pair of inner surfaces is obtained;

combining the partial molds to form the internal cavity;

injecting a material in a fluidized state into the cavity;

solidifying the material;

separating the combined partial molds and taking out an intermediate member;

applying machine work to the intermediate member to obtain the cover housing;

fixing the camera main body section to the cover housing with a fixing member; and

connecting the circuit board and the camera main body, wherein

the camera main body section includes a lens unit,

the top plate section of the cover housing includes a pedestal extending downward,

the camera main body section includes, on a surface thereof, a camera flat face, which is a flat face,

a pair of inner surfaces of the molds that sandwich the tabular part in the internal cavity are surfaces of the partial molds different from each other,

one of the pair of inner surfaces includes a recessed section,

depth of the recessed section measured with reference to a flat part of the one inner surface is larger than height of the pedestal,

the machine work includes machining for cutting a distal end of the pedestal and forming a pedestal flat face, which is a flat face facing a predetermined direction,

in a state in which the camera main body section is fixed to the cover housing, the pedestal flat face and the camera flat face are in contact with each other, and

the predetermined direction is determined with reference to an inclination angle of the windshield of a target vehicle body, a relative direction of an optical axis of the lens unit with respect to the camera flat face, relative directions of the pedestal flat face and an upper face of the top plate section, and relative directions of the top plate and the windshield surface in a state in which the vehicle-mounted camera is attached to the windshield,

the circuit board includes a processing circuit element that electronically processes an image photographed by the camera main body section,

the processing circuit element includes an image processing program for using a direction error in processing the image photographed by the camera main body section,

the camera main body section after being attached to the windshield of the target vehicle body photographs a target object present in a known direction, which is a direction known with respect to the vehicle body, and causes the processing circuit element to acquire an image,

the processing circuit element recognizes an on-image position, which is a position of the target object on the image, the processing circuit element recognizes an original position, which is a position where the target object should originally be present on the image, on the basis of the known direction,

the processing circuit element calculates the direction error using the original position and the on-image position, and painting at least the upper face of the top plate section on a surface of the intermediate member, wherein

the machine work cuts at least a part of a painted surface of the intermediate member,

the painting is executed before the camera main body section is fixed to the cover housing by the fixing member.

6. The method of manufacturing the vehicle-mounted camera according to claim 3, wherein the predetermined direction is determined further with reference to a photographing direction in which the camera main body section photographs a scene and a tolerance allowed for the photographing direction.

7. The method of manufacturing the vehicle-mounted camera according to claim 3, wherein

the camera main body section further includes a protrusion section for fixing that is a part extending in a direction away from the optical axis,

both of the material and the protrusion section for fixing are aluminum or an aluminum alloy,

the camera flat face is located on a surface of the protrusion section for fixing, and

metal surfaces of both of the pedestal flat face and the camera flat face are exposed.

11. The method of manufacturing the vehicle-mounted camera according to claim 3, wherein the predetermined direction is determined further with reference to a photographing direction in which the camera main body section photographs a scene and a tolerance allowed for the photographing direction.

14. The method of manufacturing the vehicle-mounted camera according to claim 3, wherein more than half of a lower face of the top plate section is a painted surface.

16. The method of manufacturing the vehicle-mounted camera according to claim 6, wherein more than half of a lower face of the top plate section is a painted surface.

17. The method of manufacturing the vehicle-mounted camera according to claim 7, wherein more than half of a lower face of the top plate section is a painted surface.